Folding spoon, method and apparatus for manufacturing such folding spoon

The patent employs disposable paperboard spoons instead of reusable plastic cutlery. The spoon is designed as a single-use item made from biodegradable paperboard material, eliminating the environmental persistence problem of plastic while maintaining functional adequacy for takeaway food consumption. The disposable nature resolves the contradiction by accepting short lifespan in exchange for environmental compatibility.

The spoon is attached to the food container itself, with the spoon nested within or integrated to the container structure. This eliminates the need for separate loose packaging boxes while maintaining hygiene by keeping the spoon enclosed with the sealed food container until use. The attachment mechanism allows the spoon to be provided in a hygienic state directly with the food product.

The spoon is designed as a foldable structure that can be segmented into multiple parts (handle, bowl, and connecting sections with folding lines). This allows the spoon to be collapsed into a compact form that fits within the small diameter container, while maintaining full functionality when unfolded for use. The segmentation enables the spoon to adapt its size for storage while preserving its operational dimensions.

The retention mechanism is merged into the spoon structure itself through the formation of retention flaps that are integral parts of the paperboard blank. These flaps are formed during the punching and folding process, eliminating the need for separate retention components. The retention function is combined with the structural elements of the spoon, simplifying the overall manufacturing process while maintaining the environmental benefits of paperboard material.

The spoon structure includes self-retaining flaps that automatically maintain the folded condition without requiring external clamping elements. The retention flaps are formed as integral parts of the spoon blank and automatically engage when the spoon is folded, providing self-service retention functionality. This eliminates the need for separate clamping operations, significantly reducing manufacturing time while maintaining reliable retention of the folded state.

The spoon blank is pre-formed with embossed folding lines and score markings that guide the folding process. These preliminary markings are created during the blank manufacturing stage, allowing the cavity structure to be formed systematically during assembly. The pre-established folding guides simplify the manufacturing process by providing clear instructions for creating the cavity shape, reducing the complexity of the folding operations required.

The patent introduces retention flaps as intermediary elements that facilitate automatic folding and maintain folding consistency. These flaps act as mechanical guides and stoppers during the automated folding process, ensuring that each spoon is folded to the same precise position. The retention flaps mediate between the folding mechanism and the final folded state, providing consistent results across high-volume production while enabling automated operation.